Abstract
This paper deals with the design of an energy management strategy (EMS) for an industrial hybrid self-guided vehicle (SGV), considering the size of a fuel cell (FC) stack and degradation of a battery pack. In this context, first, a realistic energy model of the SGV was proposed and validated, based on experiments. This model provided a basis for individual components analysis, estimating energy requirements, component sizing, and testing various EMSs, prior to practical implementation. Second, the performance of the developed FC/battery SGV powertrain was validated under three EMS modes. Each mode was studied by considering four different FC sizes and three battery degradation levels. The final results showed that a small FC as a range extender is recommended, to reduce system cost. It is also important to maintain the FC in its high efficiency zones with a minimum ON/OFF cycle, leading to efficiency and lifetime enhancement of FC system. Battery SOC have to be kept at a high level during SGV operation, to support the FC during SGV acceleration. In order to improve the SGV’s overall autonomy, it is also important to minimize the stop and go and rotational SGV motion with appropriate acceleration and deceleration rate.
Highlights
In the context of industry 4.0, the issue of indoor material handling and transportation by low-speed vehicles, such as mobile robots, is a frequently discussed topic [1]
This study analyzed the performance of an industrial self-guided vehicle (SGV) energy management strategy (EMS) for different fuel cell (FC) sizes and battery degradation levels
A realistic energy model, which was the core of the proposed analysis, was developed for the studied SGV
Summary
In the context of industry 4.0, the issue of indoor material handling and transportation by low-speed vehicles, such as mobile robots, is a frequently discussed topic [1]. Differential drive mobile robots (DDMRs) are the most common and popular way to drive SGVs, due to their simplicity and zero-radius turning [3] In this context, the electric powertrains and especially the battery based powertrains were proposed to replace the internal combustion engines (ICEs) in industrial vehicle applications [4]. A primary method is to choose a bigger battery in terms of capacity, which in turn would increase the cost and the recharge time Another notable drawback of the battery is its limited life cycle. The lifespan of a lithium battery varies from 500 to 1500 charge/discharge cycles, depending on the utilization pattern [5] Another solution is to extend the SGV autonomy by adding a second power source like a proton exchange membrane fuel cell (PEMFC) system. A PEMFC can be charged in just a few minutes and Energies 2020, 13, 5041; doi:10.3390/en13195041 www.mdpi.com/journal/energies
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